Chromalox CMX Installation guide

Brand: Chromalox

Model: CMX

Type: Installation guide

Installation & Operation Manual

Circulating Water

Temperature Control System

PQ450-1

161-123417-036

January 2020

Table of Contents

Contents Page Number

Section 1 Getting Started ...................................................................................................................................... 1

Section 2 Installation .............................................................................................................................................. 4

Section 3 Temperature Control Operation ........................................................................................................... 9

Section 4 System Operation ................................................................................................................................ 10

Section 5 Diagnostics .......................................................................................................................................... 11

Section 6 Maintenance ........................................................................................................................................ 12

Section 7 Troubleshooting ................................................................................................................................... 17

Section 8 Speciﬁcations ...................................................................................................................................... 18

Appendix A CMX Closed Loop to Open Loop Cooling Conversion ................................................................. 19

Appendix B CMX Open Loop to Closed Loop Cooling Conversion ................................................................. 20

Appendix C CMX 2104 Controller Information .................................................................................................. 23

Section 1 – Getting Started

Installation Instructions

Read and understand all instructions in this

user’s manual and the associated temperature

control instruction manual before attempting

to install or operate system.

Introduction

Congratulations on purchasing the Chromalox CMX

Series microTHERM™ Temperature Control System.

This system has been thoroughly engineered, carefully

built, and fully tested to assure years of service.

The CMX can be operated at a maximum tempera-

ture of 250°F at a minimum pressure of 30psi. CMX-

180 models do not require minimum pressure. Water

temperature is maintained by a microprocessor-based

temperature controller which applies heating and cool-

ing as needed. Heat is applied by a long-life, INCOLY

sheathed heater. Cooling is either via direct injection, in

an open loop, or through a closed loop heat exchanger.

Every system is equipped with an automatic vent that

removes unwanted air from the system during opera-

tion, and an ASME pressure relief valve that is factory-

set to 125 psi (150 psi with 7.5 hp motor.) A pressure

switch ensures adequate water pressure in the system

to help prevent pump cavitation and steam buildup on

the heater elements, which can shorten the lives of the

heater and pump. The switch is factory-set to 20 psi.

This switch is not included on CMX-180 models.

Electrical and hydraulic components are located in

distinctly separate areas in the system to better man-

age heat buildup and prevent component damage.

The pump housing, heater, and cooling chambers are

single cast pieces, designed to drastically reduce the

chance of leaks and provide ease of service and main-

tenance. Standard casters make it easy to move the

system from machine to machine.

Power requirements for the system are 240 or 480

volts, 3 phase, 60 cycle, and 4.5 to 24 kW. See the sys-

tem nameplate for the appropriate voltage and wattage

ratings.

The System Photo and Control Panel Illustrations, on

the following pages, show the CMX and identiﬁes all

key components.

Figure 1.1 System Photo (Side View)

Operating temperatures of 50° to 250°F

for a wide variety of applications.

ASME pressure relief valve opens if sys-

tem pressure exceeds 125 psi, ensuring

safe operation.

High watt density, INCOLOY

sheath

Chromalox

heating elements.

Integral solenoid valve for pre-

cise temperature control and

optimum flow.

Internal system configuration separates

electronics from mechanical systems,

reducing heat buildup and providing

a safer operating system.

Pump overload circuit protects

systems from damage in event

of excessive current draw in

the motor.

Long-life mercury contactor switches

heater power for millions of cycles and

quiet, trouble-free operation.

Compact, rugged cabinet fits into tight

spaces. Rolling casters allow easy

transfer between locations.

Low pressure switch disables system when

supply pressure is low, preventing cavitation in

pump and protecting the system.

Custom cast pump for optimum flow,

minimum leakage and long life.

Cabinet design allows

access to all compo-

nents without removing

a single fastener.

Standard 3.8 sq. ft. heat ex-

changer (closed loop cool-

ing)

Automatic air purge cycle

removes accumulated air

from water lines.

Dual pressure gauges simplify monitoring of both

to process and from process pressures.

Chromalox’s Temperature and Process Controller

features separate PID algorithms for heat and

cool control modes, dual display of setpoint and

process temperatures, and simple configuration

parameters with alphanumeric cues. Optional

digital communications expand microTHERM’s

application flexibility. (Controller model supplied

may vary from picture)

Diagnostic Indicators allow you to constantly

monitor microTHERM’s performance, giving you

early detection of potential problems before they

occur and simplifying maintenance.

Figure 1.2 Control Panel

Ordering Information

Pump START/STOP Pushbuttons

kW Volts Ph.

Pump

Motor

Dimensions

(In.)

Cooling Type Model Stock Part Number

Wt.

(Lbs)H W D

4.5 240 3 3/4 29 15 25 Open Loop CMX-250-4 NS 307418-032 200

4.5 480 3 3/4 29 15 25 Open Loop CMX-250-4 NS 307418-033 200

4.5 240 3 3/4 29 15 25 Closed Loop CMX-250-4C NS 307418-042 215

4.5 480 3 3/4 29 15 25 Closed Loop CMX-250-4C NS 307418-043 215

9 240 3 3/4 29 15 25 Open Loop CMX-250-9 NS 307418-034 200

9 480 3 3/4 29 15 25 Open Loop CMX-250-9 S 307418-035 200

9 240 3 3/4 29 15 25 Closed Loop CMX-250-9C NS 307418-044 215

9 480 3 3/4 29 15 25 Closed Loop CMX-250-9C S 307418-045 215

12 240 3 3/4 29 15 25 Open Loop CMX-250-12 NS 307418-036 200

12 480 3 3/4 29 15 25 Open Loop CMX-250-12 S 307418-037 200

12 240 3 3/4 29 15 25 Closed Loop CMX-250-12C NS 307418-046 215

12 480 3 3/4 29 15 25 Closed Loop CMX-250-12C S 307418-047 215

18 240 3 3/4 29 15 25 Open Loop CMX-250-18 NS 307418-038 200

18 480 3 3/4 29 15 25 Open Loop CMX-250-18 S 307418-039 200

18 240 3 3/4 29 15 25 Closed Loop CMX-250-18C NS 307418-048 215

18 480 3 3/4 29 15 25 Closed Loop CMX-250-18C S 307418-049 215

24 240 3 3/4 29 15 25 Open Loop CMX-250-24 NS 307418-040 200

24 480 3 3/4 29 15 25 Open Loop CMX-250-24 S 307418-041 200

24 240 3 3/4 29 15 25 Closed Loop CMX-250-24C NS 307418-050 215

24 480 3 3/4 29 15 25 Closed Loop CMX-250-24C S 307418-051 215

36 480 3 3/4 29 15 25 N/A CMX-250-36H NS 307418-052 215

48 480 3 3/4 29 15 25 N/A CMX-250-48H S 307418-053 215

Section 2 – Installation

Before Open-Loop Hydraulic Installation:

Before proceeding with the installation of the open-

loop system, please take note of the following impor-

tant information:

1. Reduced diameter ﬁttings may be used if they do

not reduce ﬂow rate and increase pressure drop

signiﬁcantly. Galvanized steel unions are recom-

mended at all connections.

2. If water pressure falls below 20 psi, a pressure

switch will interrupt pump motor and heater op-

eration. Use an external water pressure regulator

and back pressure relief valve or regulator, set at

maximum 125 psi (150 psi with 7.5 hp motor) con-

nected in the external ﬁll line, to reduce excessive

water pressure. Not provided on CMX-180 models.

HAZARD OF EXPLOSION, FIRE AND SCALDING

BURNS.

The water feed line on both open and closed

loop systems must not have any obstructions

which could prevent expanding water from

backing up into the feed line.

Do not use oils or other synthetic heat trans-

fer ﬂuids. This system is for use with water or

ethylene glycol and water mixture for freeze

protection only as the heat transfer ﬂuid.

When installing system, allow sufﬁcient room

to remove the heater element and other ser-

viceable items when necessary. 18 inches

clearance on sides of unit recommended.

If the water source is a potable water source,

a back ﬂow preventer and back pressure relief

valve/regulator should be installed and may be

required by local code. Do not install a check

valve only on the ﬁll line. The inability of the

system to ﬂow back into the ﬁll line can lead

to excessive pressure. Back pressure relief is

required.

To avoid excessive pressures, do not connect

any valves or obstructions which could prevent

free discharge from relief valve in a safe man-

ner. Route line so water drains completely. Do

not allow drain to freeze or corrode shut.

Hydraulic Installation, Open Loop:

1. Locate the unit as close as possible to the con-

trolled process in order to minimize pressure

drops. Make sure the unit is sitting on a solid, level

foundation.

2. Using 1-1/2” NPT or larger schedule 40 pipe (ﬂex-

ible hose suitable for 150 psi and 250°F minimum

service conditions can be used), connect the

1-1/2” NPT “FROM PROCESS” and “TO PRO-

CESS” ports to the mold, mold manifold, or other

process.

3. Pipe the entire system to minimize air pockets.

Provide air bleed valves at high points and drains

at low points.

4. Connect the plant water supply (30 psi to 80 psi)

to the unit’s 1” NPT “WATER SUPPLY/COOLING

INLET” port with suitable pipe or hose.

HAZARD OF EXPLOSION, FIRE AND SCALDING

BURNS.

Connect the 1/4” NPT port identiﬁed as “DRAIN

COOLING OUTLET” to an open or plant drain

that contains no valves or obstructions that

could impede discharge. Review the condition

of potential hot water or steam going down a

plant drain. Verify that local codes and materi-

als are acceptable for this service.

Locate ﬂoor drain under unit. The air bleed and

relief valve may discharge hot water or steam

from the bottom of the unit. Do not locate ma-

terials that could be damaged by hot water or

steam adjacent to the unit.

Temperature Controller

Drain/Cooling

Outlet

(1/4 NPT)

From Process

(1-1/2 NPT)

Water Supply/

Cooling Inlet

(1 NPT)

Pump and

Motor

Pressure

Relief

Valve

Auto

Air Bleed

Heater

Therocouple

Probe

To Process

(1-1/2 NPT)

Heater

Cooling

Valve

Temperature Controller

Cooling Outlet

(1/2 NPT)

From Process

(1-1/2 NPT)

Water Supply/

Cooling Inlet

(1/2 NPT)

Auto

Air Bleed

Pressure

Relief

Valve

Therocouple

Probe

To Process

(1-1/2 NPT)

Solenoid

Valve

Pump and

Motor

Figure 2.1 Open-Loop System Piping

Figure 2.2 Open-Loop Cooling Piping Connections

Note: Dimensions are nominal ± 3/8”

Rear View

Chromalox

DRAIN/

COOLING OUTLET

FROM PROCESS

PROCESS

1-7/8”

15"

WATER SUPPLY/

COOLING INLET

12-5/16”

28-1/2”

Before proceeding with the installation of the Closed-

loop system, please take note of the following informa-

tion:

1. Reduced diameter ﬁttings may be used if they do

not reduce ﬂow rate and increase pressure drop

signiﬁcantly. Galvanized steel unions are recom-

mended at all connections.

2. If water pressure falls below 20 psi, a pressure

switch will interrupt pump motor and heater op-

eration. Use an external water pressure regulator

and back pressure relief valve or regulator set at

maximum 125 psi (150 psi with 7.5 hp motor) con-

nected in the external ﬁll line, to reduce excessive

water pressure. Not provided with CMX-180 mod-

els.

HAZARD OF EXPLOSION, FIRE AND SCALDING

BURNS. To avoid excessive pressures, do not

connect any valves or obstructions which could

prevent free discharge from relief valve in a

safe manner. Route line so water drains com-

pletely. Do not allow drain to freeze or corrode

shut.

Do not install a check valve on the ﬁll line. The

inability of the system to ﬂow back into the

ﬁll line can lead to excessive pressure. If back

ﬂow preventer or check valve is required, in-

stall back pressure regulator rated for 250°F

water with a pressure setting of 30 to 80 psi.

Back pressure regulator setting must be ap-

proximately 10 psi above water supply pres-

sure to minimize water ﬂow directly from sup-

ply to drain.

Hydraulic Installation Closed-Loop

1. Locate the unit as close as possible to the con-

trolled process in order to minimize pressure

drops. Make sure the unit is sitting on a solid, level

foundation.

2. Using 1-1/2” NPT or larger schedule 40 pipe (ﬂex-

ible hose suitable for 150 psi and 250°F minimum

service conditions can be used), connect the

1-1/2” NPT “FROM PROCESS” and “TO PRO-

CESS” ports to the mold, mold manifold, or other

process.

3. Pipe the entire system to minimize air pockets.

Provide air bleed valves at high points and drains

at low points.

4. Connect the cooling water supply (30 psi to 80 psi)

to the unit’s 1/2” NPT “WATER SUPPLY/COOLING

INLET” port with suitable pipe or hose.

5. Connect the 1/4” NPT port identiﬁed as “COOL-

ING OUTLET” to a cooling water return line or plant

drain that contains no valves or obstructions that

could impede discharge. Review the condition of

potential hot water going down a plant drain. Verify

that local codes and materials are acceptable for

this service. Temperature of discharge water could

reach 250°F and create steam at atmospheric

pressure.

Temperature Controller

Drain/Cooling

Outlet

(1/4 NPT)

From Process

(1-1/2 NPT)

Water Supply/

Cooling Inlet

(1 NPT)

Pump and

Motor

Pressure

Relief

Valve

Auto

Air Bleed

Heater

Therocouple

Probe

To Process

(1-1/2 NPT)

Heater

Cooling

Valve

Temperature Controller

Cooling Outlet

(1/2 NPT)

From Process

(1-1/2 NPT)

Water Supply/

Cooling Inlet

(1/2 NPT)

Auto

Air Bleed

Pressure

Relief

Valve

Therocouple

Probe

To Process

(1-1/2 NPT)

Solenoid

Valve

Pump and

Motor

Figure 2.3 Closed-Loop System Piping

Before Closed-Loop Hydraulic Installation

Figure 2.4 Closed-Loop Cooling Piping Connections

Chromalox

COOLING OUTLET

WATER SUPPLY/

COOLING INLET

FROM PROCESS

PROCESS

1-7/8”

15"

12-5/16”

28-1/2”

Rear View

Note: Dimensions are nominal ± 3/8”

HAZARD OF ELECTRIC SHOCK. The heat trans-

fer system must be grounded using grounding

means provided in control box and employing

wiring by a qualiﬁed electrician in accordance

with National Electric Code. Failure to comply

can result in electrical shock or electrocution.

HAZARD OF ELECTRIC SHOCK. Disconnect all

power before servicing the heat transfer sys-

tem. Failure to comply can result in electrical

shock or electrocution.

Fusing or other over-current protection must be sup-

plied to the system by the user.

The unit is completely wired when shipped. The only

wiring necessary is to the blue colored terminals L1,

L2, L3, and the green and yellow colored ground. To

make these connections:

Figure 2.5 Power Connection Terminals

1. Loosen the screw on the front electrical enclosure

door to unlock the latch.

2. Open the front electrical enclosure door. Using

90°C wire sized per National and local codes, run

each leg of the three phase supply power and

ground to the appropriate terminals as shown in

Figure 2.5.

3. A separate fused disconnect is required. Locate

this fused disconnect near the equipment. Codes

may require the location of disconnect in sight of

operation standing next to the equipment. Consult

applicable codes for details.

4. Pump Rotation Check: With power off, check the

wiring connections by tugging on the lines. Tighten

all terminals in the control area. These can loosen

due to vibration in shipping.

5. Close the front electrical enclosure door. Pull the

top cover off of the heat transfer system and locate

the top of the pump motor.

6. With the supply water connected, and adequate

pressure present, Press the

ART STOP

and

START

STOP

but-

tons in quick succession. Watch the rotation on the

pump motor to insure it matches the label on its

top.

7. If rotation is incorrect, disconnect power to the

system and swap any two of the supply lines. Re-

peat rotation check.

Close the front electrical enclosure door and

retighten the locking screw. This must be done

to limit access to high voltage components.

Failure to comply could lead to electric shock

or electrocution.

Control Voltage Fusing

Terminal block #1 (see Figure 2.5) contains a 120V fuse

for the control circuitry. This fuse protects the control

transformer and circuitry.

1. Should the fuse blow, an indicator will light on the

terminal block.

2. Disconnect power from the system.

3. Determine the cause of the blown fuse.

4. Replace with an equivalent fuse.

5. Reconnect power.

Electrical Installation

Section 3 – Temperature Control Operations

Figure 3.1 Control Panel Layout

Status and Diagnostic Indicators

System shuts down if any red diagnostic indicator is

illuminated.

Low Water Pressure:

• System water pressure is below 20 psi.

(Disabled on CMX-180 models)

Pump Overload:

• Pump has drawn too much current.

Over Temperature:

• System temperature has exceeded 260°F.

Most CMX units shipped from 1995 through 2018 will

have been equipped with a Chromalox model 2104

temperature controller. For these units, please refer-

ence the 2104 Quick Info Manual or Instruction Manual

0037-75276 for complete technical details.

For speciﬁc controller Set-up Parameters, please refer

Chromalox Manual PQ445-5

Most CMX units shipped from 2019 and onward will

have been equipped with a Chromalox model 4081

(standard controller) or 4082 (advanced controller). For

these units, please reference the 4081 & 4082 Quick

Start Manual, Document PK531 (0037-75563) or In-

struction manual PK532-1 (0037-75562) for complete

technical details.

Below is a list of the most common controller setups,

with additional details available in Appendix C

CMX-250, Contactor – Dwg. 223-123625-053

CMX-275, Contactor – Dwg. 223-123625-052

CMX-250, SCR – Dwg. 223-123625-055

CMX-275, SCR – Dwg. 223-123625-058

CMX-250, Heat-Only – Dwg. 223-123625-057

CMX-275, Heat-Only – Dwg. 223-123625-059

START/STOP Pushbuttons

Press

ART

STOP

to start the

pump.

Indicator will illuminate while

pump is running. Press

START

STOP

to stop the pump.

Temperature Control

Actual controller supplied may vary from picture.

On both open Closed-loop systems, turn on wa-

ter and insure the water supply lines are free

of obstructions BEFORE energizing the heater.

Such obstructions could prevent the thermal

expansion of water from backing up into this

line, thereby increasing system pressure until

the relief valve opens.

Note: This system is equipped with an ASME

safety pressure relief valve (factory preset at

125 psi or 150 psi with 7.5 hp motor).

1. Apply power to the system via the remote discon-

nect. The temperature controller and “LOW WATER

PRESSURE” diagnostics light should illuminate.

2. Open supply-water line and process valving to al-

low system to ﬁll. Auto air bleed will remove air from

the system. Any remote air bleed valves should be

opened to remove air from process and associated

piping.

3. “LOW WATER PRESSURE” diagnostic light should

go out when the system is ﬁlled and has reached

20 psi. The system will not start when light is illumi-

nated.

4. Adjust the temperature setpoint to the desired lev-

el.

5. Assure that Pump Rotation Check was performed

per instructions on page 12.

6. Start the pump by pressing on the front panel. The

pump indicator light will illuminate.

7. Once temperature has stabilized at the setpoint

level, review controllability of the system. If the

temperature is ﬂuctuating at an unacceptable level,

consult the temperature control instruction manual

for details on tuning the controller.

8. If the system temperature is below the current set-

point, heat will be applied by the controller to the

heater elements. If the temperature is above the

setpoint, the cooling solenoid will open (open and

closed loop) to reduce the system temperature.

Operating systems at temperatures above

140°F will create surface temperatures on

pipes that can cause burns. Precautions should

be taken to prevent operator contact with hot

pipes. Also, bleed valves should be locked

down to prevent release of hot ﬂuid.

Note: This is a PID type controller and cycling of the

heat and cool can be expected below and above set-

point.

9. For system shutdown, lower the setpoint to 90°F or

lower, Allow the system to cool to this temperature

level.

10. Press to de-energize the pump and disable the

system.

11. Disconnect power to the unit.

Do not leave system unattended in a HOT elec-

trical condition; and do not leave system unat-

tended in HOT environmental conditions.

Section 4 – Operation

Section 5 – Diagnostics

Figure 5.1 Diagnostic Indicators

Diagnostic Functions

All diagnostic functions will shut down the system and

require the operator to remedy the problem before it

can be restarted.

Low Water Pressure Indicators

The pump, heater, and cooling will not operate while

the pressure is low. The Low Water Pressure Indica-

tor will illuminate when the system pressure is below

20 psi. This warning system is designed to reduce the

possibility of pump cavitation and boiling on the heater

element at higher operating temperatures. Disabled on

CMX-180 models.

Pump Overload Indicator

The Pump Overload Indicator will illuminate when the

pump draws too much current. Low line voltage, single

phase power input, and a seized pump motor are all

possible causes for pump overload.

HAZARD OF ELECTRIC SHOCK. Disconnect

system power, if the Pump Overload Indicator

is illuminated. Hazard of electric shock or elec-

trocution. Disconnect all power and piping to

the system.

After the system power is disconnected, solve the

electrical current problem. To put the pump back on-

line, open the front electrical enclosure and press the

pump reset switch (See Figure 5.2, Overload Switch).

Figure 5.2 Pump Reset Switch

Close the front electrical enclosure door and

retighten the locking screw. This must be done

to limit access to high voltage components.

Failure to comply could lead to electric shock

or electrocution.

Over Temperature Indicator

If the system temperature exceeds 260°F (127°C), the

Over Temperature Indicator will illuminate. When the

system temperature drops below 260°F*, press RE-

SET on the controller face. The controller will not reset

until the temperature is below 260°F*.

190°F on CMX-180 model(s)

ELECTRIC SHOCK AND BURN HAZARD. Discon-

nect all power before servicing or performing

maintenance to the system. Do not attempt to

service system while it is operating or while

hot. Failure to comply can result in:

a. Electric shock.

b. Burns from hot heating elements, piping,

and hot oil or water.

c. Injury from operating or rotating pump and

motor.

Maintenance is to be performed by qualiﬁed

personnel only. Thoroughly read and under-

stand these instructions. Consult the factory if

you have any questions.

Shut Down

To take the unit out of service, the following steps must

be done in sequence:

1. Set the temperature controller setpoint to 90°F or

lower. Allow to cool.

2. Turn off power to the unit. The controller will turn

off.

3. Turn off the water supply to the unit.

4. Disconnect electrical supply to the unit.

5. Carefully bleed pressure from the system by loos-

ening a pipe ﬁtting.

System may be pressurized. Use extreme care

while removing piping. Disconnect water sup-

ply, drain and process connections.

6. Drain all water from the system.

Draining

Drain the unit before taking it out of service for a pe-

riod of time, or if it is exposed to freezing temperatures

while out of service.

1. To drain the unit completely, move it to an inclined

position with the front of the system raised.

2. Remove the lower plugs on cast chambers (see

Figure 6.1, Chamber Photo).

Figure 6.1 Chamber Photo

Remove these

plugs

Section 6 – Maintenance

Heater Removal/Replacement

HAZARD OF ELECTRIC SHOCK. Disconnect all

power and piping to system.

1. Disconnect all power to the system.

2. Bleed pressure and drain all water from the sys-

tem.

3. Remove top panel.

4. Remove red top cover on the heater (see Figure

6.2, Heater/Chamber Photo).

5. Note location of wires on the heater, then remove

wires (L1, L2, L3).

6. Loosen compression ﬁtting on the heater power

supply cable.

7. Remove cable from the heater.

8. Unbolt the heater (4 bolts) and remove.

9. Remove Bussing from old heater and re-install on

replacement heater, using the same orientation.

10. Replace heater and reverse procedure.

Close the front electrical enclosure door and

retighten the locking screw. This must be done

to limit access to high voltage components.

Failure to comply could lead to electric shock

or electrocution.

Figure 6.2 Heater/Chamber Photo

Remove Top Cover

on Heater

Remove Top Panel

Pump Removal/Replacement

HAZARD OF ELECTRIC SHOCK. Disconnect all

power and piping to system.

1. Disconnect all power to the system.

2. Bleed pressure and drain all water from the sys-

tem.

3. Remove top and side panels.

4. Remove pump motor wiring cover panel (2 screws).

5. Note location of pump motor wires and remove.

6. Loosen and remove vent line (see Figure 6.3, Motor

Vent Line).

7. Remove bolts holding pump motor to the casting

(4 bolts), and lift motor out of casting.

8. Remove impeller and install new mechanical seal

and impeller on the new motor.

9. Place new motor in system and bolt down.

10. Replace vent line and tighten.

11. Reconnect wires and replace wiring cover and side

panels.

12. Reconnect the system.

13. Perform Pump Rotation Check (see Section 2,

page 12).

14. Replace top panel.

Close the front electrical enclosure door and

retighten the locking screw. This must be done

to limit access to high voltage components.

Failure to comply could lead to electric shock

or electrocution.

Pump /Motor Vent Line

Heater Element

Housing

Motor

Pump Housing

Figure 6.3 Motor Vent Line

Heat Exchanger Removal/Replacement

(Closed loop system)

1. Disconnect all power to the system.

2. Bleed pressure and drain all water from the system.

3. Remove top panel.

4. Remove cover on the cooling solenoid (see Figure

6.4, Heat Exchanger).

5. Disconnect “COOLING INLET” and “COOLING

OUTLET” piping.

6. Disconnect copper tubing connected to the heat

exchanger.

7. Unbolt the heat exchanger and remove (4 bolts).

8. Place new heat exchanger in system and bolt

down.

9. Reconnect “COOLING INLET” and “COOLING

OUTLET” piping.

10. Reconnect wires to the cooling solenoid.

11. Reconnect copper tubing.

12. Replace cover on cooling solenoid and top panel.

13. Replace system water and reconnect the system.

Close the front electrical enclosure door and

retighten the locking screw. This must be done

to limit access to high voltage components.

Failure to comply could lead to electric shock

or electrocution.

Top Panel

Cooling Solenoid

Heat Exchanger

Figure 6.4 Heat Exchanger

Replacement Heating Elements and Contactors

MicroTHERM Model Replacement Parts

Open Loop Closed Loop Voltage Heating Element Heater Contactor

CMX-4 CMX-4C 240 155-554807-523 072-057576-050

CMX-4 CMX-4C 480 155-554807-523 072-057576-050

CMX-9 CMX-9C 240 155-554807-512 072-057576-050

CMX-9 CMX-9C 480 155-554807-512 072-057576-050

CMX-12 CMX-12C 240 155-554807-524 072-057576-050

CMX-12 CMX-12C 480 155-554807-524 072-057576-050

CMX-18 CMX-18C 240 155-554807-519 072-057576-051

CMX-18 CMX-18C 480 155-554807-519 072-057576-050

CMX-24 CMX-24C 240 155-554807-515 072-057576-051

CMX-24 CMX-24C 480 155-554807-515 072-057576-050

Replacement Parts Common to All Models

Identiﬁcation # Part Name Part Number

1 3/4 HP Motor 240V/480V 193-121843-227

2 Solenoid Valve 344-121780-012

3 Pressure Relief Valve 344-048419-004

4 Automatic Air vent 344-053181-001

5 Pressure Gauge 130-118661-021

6 Pressure Switch 292-121927-028

7 Pump Mechanical Seal 251-121946-019

8 Heat Exchanger Bundle (Closed Loop) 353-123367-002

9 Heater/Cooling Gasket (2 total) 132-146012-020

10 Thermocouple 309-121759-063

11 Switch, Start/Stop

Switch Indicator Bulb

292-122882-043

213-122066-034

12 Diagnostic Indicator Light (3 total) 213-122066-041

13 Motor Contactor 240/480V 072-123534-064

14 Auxillary Motor Contact Block 071-122886-055

15 Motor Thermal Overload 240V

Motor Thermal Overload 480V

359-122078-096

359-122078-095

16 Transformer 240/480V 315-303786-001

17 Caster (4 total) 375-123425-003

18 Control Voltage Fuse 128-123445-005

19 Heater Contactor See table above

These parts may vary for non-catalog items.

Please consult your local Chromalox representative. (800-443-2640 or www.chromalox.com)

Figure 6.6 Replacement Parts Identiﬁcation

From Process

To Process

START

Pump

System Diagnostics

Low Water Pressure

Pump Overload

Over Temperature

RESETAUX

PAGE

HEAT

COOL

OUT3

OUT4

AUX

Chromalox

CMX Series

Temperature Control System

HEATER

CONTACTOR

TRANSFORMER

AUX. CONTACT BLOCK

FUSE

CONNECT

_____VOLT

SUPPLY

HERE

MOTOR CONTACTOR

MOTOR THERMAL

OVERLOAD

Chromalox

Section 7 – Troubleshooting

Troubleshooting Guide - For qualiﬁed personnel only. See warnings in earlier sections.

Symptom Probable Cause Correction

Unit will not start, control

display does not light.

1. Unit not wired correctly. 1. Check wiring.

2. Disconnect switch OFF. 2. Turn disconnect ON.

3. Blown fuse. 3. Check customer disconnect fuses and

120V fuse on terminal block (blown fuse indi-

cator will light if fuse is blown).

4. Wrong voltage. 4.

Check supply voltage & unit’s rated voltage.

Control display lights, unit

will not start

1. Cooling water off, or below 20

psi. (CMX-250 models only)

1. Open cooling water valve, check to assure

pressure is above 30psi

2. Pump Motor Overload 2. Determine problem and press pump reset.

3. System above temperature

limit of 260°F. (190˚F on CMX-

180 Models)

3. Allow unit to cool below 260°F and press

RESET.

Unit stops while running

1. Cooling water drops below 20

psi

1. Check cooling water valve, check to as-

sure above 30 psi

2. Pump motor overload 2. Determine problem and press pump reset.

3. System exceeds temperature

limit of 260˚F (190˚F on CMX-180

Models)

3. Allow unit to cool below 260°F and press

RESET.

Low Water Pressure

Indicator Illuminated

1. Cooling water drops below 20

psi (CMX-180 models)

1. Check that pressure is above 30 psi

Pump Overload Indicator

illuminated

1. Pump motor overload 1. Determine the problem and press pump

reset button

Over Temperature

Indicator illuminated

1. System above temperature

limit of 600°F.

1. Allow unit to cool below 550°F and press

reset on over temperature controller inside

the panel. See Section 5.

Unit runs but fails to

pump.

1. Incoming phase reversed on

pump motor.

1. Swap any two legs on the incoming power.

Unit will not heat to

setpoint.

1. Cooling valve stuck open. 1. Check for cooling water ﬂow during heat

cycle.

2. Heater element failure. 2. Check current at heater contactor during

heating.

3. Heater output insufﬁcient. 3. Excessive losses in process or incorrectly

sized unit for application.

4. Controller needs to be tuned. 4. Check factory MENU settings, Section 3 of

this manual. Refer to 2104 Controller Techni-

cal Manual, page 35, for further information.

Unit will not cool to

setpoint.

1. Inadequate cooling water ﬂow. 1. Open cooling water supply line more and

assure adequate pressure.

2. Cooling outlet obstructed. 2. Check cooling outlet for obstructions

3. Heater contactor fused

closed.

3. Check voltage across contactor during

cooling cycle.

4. Controller needs to be tuned. 4. Check factory MENU settings, Section 3 of

this manual. Refer to 2104 Controller Techni-

cal manual, page 35, for further information.

If you continue to have problems with the system after review of the above issues, please contact Chromalox

Product Service at 800-443-2640.

Section 8 – Speciﬁcations

Optional Pump Sizes

Optional Pump Sizes (HP) Nominal Flow (gpm)

1.5 40

3 50

5 60

7.5 80

Optional Options

• Alternate Voltages: 208, 380, 575 VAC, 3 phase

• Expanded Open Loop Cooling: increased cooling

water ﬂow

• Expanded Closed Loop Cooling: 6.3 sq. ft. heat

exchanger

• Solid State Power Control: SCR heater switching

• Surge Reduction valve: reduces water pressure

spikes

• Door Interlock: prevents operation with service

door open

• Digital Communications: for interface with Chro-

maSoft or remote PC/PLC systems

• IEC Style Contactor: for dry contact power switch-

ing

• Isolation Valve Kit: 1” ball valve for system isolation

Figure 8.1 - Pump Capacity

Pump Capacity

PSI

Ft.

180

160

140

120

100

020406080 100 120

U.S. Gallons Per Minute

3/4 HP

1.5 HP

3 HP

5 HP

7.5 HP

Five Pump sizes are available for the flow rate

appropriate to your process application.

kW Volts Ph.

Pump

Motor

Dimensions

(In.)

Cooling Type Model Stock Part Number

Wt.

(Lbs)H W D

4.5 240 3 3/4 29 15 25 Open Loop CMX-250-4 NS 307418-032 200

4.5 480 3 3/4 29 15 25 Open Loop CMX-250-4 NS 307418-033 200

4.5 240 3 3/4 29 15 25 Closed Loop CMX-250-4C NS 307418-042 215

4.5 480 3 3/4 29 15 25 Closed Loop CMX-250-4C NS 307418-043 215

9 240 3 3/4 29 15 25 Open Loop CMX-250-9 NS 307418-034 200

9 480 3 3/4 29 15 25 Open Loop CMX-250-9 S 307418-035 200

9 240 3 3/4 29 15 25 Closed Loop CMX-250-9C NS 307418-044 215

9 480 3 3/4 29 15 25 Closed Loop CMX-250-9C S 307418-045 215

12 240 3 3/4 29 15 25 Open Loop CMX-250-12 NS 307418-036 200

12 480 3 3/4 29 15 25 Open Loop CMX-250-12 S 307418-037 200

12 240 3 3/4 29 15 25 Closed Loop CMX-250-12C NS 307418-046 215

12 480 3 3/4 29 15 25 Closed Loop CMX-250-12C S 307418-047 215

18 240 3 3/4 29 15 25 Open Loop CMX-250-18 NS 307418-038 200

18 480 3 3/4 29 15 25 Open Loop CMX-250-18 S 307418-039 200

18 240 3 3/4 29 15 25 Closed Loop CMX-250-18C NS 307418-048 215

18 480 3 3/4 29 15 25 Closed Loop CMX-250-18C S 307418-049 215

24 240 3 3/4 29 15 25 Open Loop CMX-250-24 NS 307418-040 200

24 480 3 3/4 29 15 25 Open Loop CMX-250-24 S 307418-041 200

24 240 3 3/4 29 15 25 Closed Loop CMX-250-24C NS 307418-050 215

24 480 3 3/4 29 15 25 Closed Loop CMX-250-24C S 307418-051 215

36 480 3 3/4 29 15 25 N/A CMX-250-36H NS 307418-052 215

48 480 3 3/4 29 15 25 N/A CMX-250-48H S 307418-053 215

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Chromalox CMX Installation guide

Chromalox CMX Installation guide

Chromalox CMX Installation guide

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